Page 2 of 6 4. Force required to break-away (i.e., force which must be exerted to begin motion of ball) will vary depending on the media, pressure and length of time between cycles. The following data will act as a guide regarding break-away torques: Item No.:TC-0802A & TC-5000/5100 150# VALVE SIZE MAXIMUM BREAK-AWAY TORQUE DN15 (1/2") DN20 (3/4") DN25 (1") DN32 (1-1/4") DN40 (1-1/2") DN50 (2") DN65 (2-1/2") DN80 (3") 2 DN100 (4") DN125 (5") DN150 (6") 6.0 N-M ( 53.10 Lbf-in ) 8.0 N-M ( 70.80 Lbf-in ) 10.0 N-M ( 88.50 Lbf-in ) 12.5 N-M ( 110.63 Lbf-in ) 24.0 N-M ( 212.40 Lbf-in ) 30.0 N-M ( 265.50 Lbf-in ) 35.0 N-M ( 309.75 Lbf-in ) 60.0 N-M ( 531.00 Lbf-in ) 102.0 N-M ( 902.70 Lbf-in ) 150.0 N-M ( 1327.50 Lbf-in ) 210.0 N-M ( 1858.50 Lbf-in ) DN200 (8") 400.0 N-M ( 3540.00 Lbf-in ) Item No.:TC-0802A 300# VALVE SIZE MAXIMUM BREAK-AWAY TORQUE DN15 (1/2") DN20 (3/4") DN25 (1") DN32 (1-1/4") DN40 (1-1/2") DN50 (2") DN65 (2-1/2") DN80 (3") DN100 (4") DN125 (5") DN150 (6") 6.0 N-M ( 53.10 Lbf-in ) 8.0 N-M ( 70.80 Lbf-in ) 10.0 N-M ( 88.50 Lbf-in ) 12.5 N-M ( 110.63 Lbf-in ) 24.0 N-M ( 212.40 Lbf-in ) 30.0 N-M ( 265.50 Lbf-in ) 45.0 N-M ( 398.25 Lbf-in ) 79.0 N-M ( 699.15 Lbf-in ) 110.0 N-M ( 973.50 Lbf-in ) 150.0 N-M ( 1327.50 Lbf-in ) 210.0 N-M ( 1858.50 Lbf-in ) DN200 (8") 400.0 N-M ( 3540.00 Lbf-in ) The above figures were obtained at 25 degrees C., 7 bar after 24 hours.
Page 3 of 6 The only mechanism of the valve that is adjustable is the stem packing. If adjustment is required the gland bolts may be fastened. Adjustment of the gland bolts should be no more than one-quarter turn at a time. Over tightening will produce high torque and a shortened seal life. MAINTENANCE A repair kit containing two seats, two body seals, one thrust washer and stem packing is available for rebuilding each size and style valve. Be sure to specify size, style, seat and seal materials when ordering. Optional components are also available (ball, stem, handle, etc.). Refer to illustration on last page for part identification and assembly. REBUILDING WARNING- Ball Valves Can Trap Fluids in Ball Cavity When Closed If the valve has been used to control hazardous media, it must be decontaminated before disassembly. It is recommended that the following steps are taken for safe removal and disassembly: -Relieve the line pressure. -Place the valve in half-open position and flush the line to remove any hazardous material from valve. -All persons involved in the removal and disassembly of the valve should wear protective clothing such as face shield, gloves, apron, etc. CAUTION: Exercise caution that sealing and all surfaces are not damaged during disassembly, cleaning or reassembly. 1. Before removing valve from line, rotate ball into the open position. 2. Remove valve from pipeline. Place valve on a clean surface and secure by clamping or bolting. 3. Unscrew the nuts and set aside. Take body and cap apart. 4. Remove body end seal, cap seat and bolts. 5. Rotate ball into the closed position. Remove ball and body seat. 6. If it is necessary to replace stem packing, remove snap ring, handle, stopper, gland bolts and gland. Lower stem into body cavity. Remove stem packing and thrust washer. 7. Clean and inspect all components to be sure they are free from foreign matter and pit marks, paying particular attention to areas that must maintain a seal (the surface against which the seats and body end seal are installed, finished diameter on stem, ball, stem hole). These areas must be free from scratches and pitting. 8. Light marring from the action of the ball against the seats is normal and will not affect the operation. 9. Once all components have been cleaned inspected and replaced as necessary, the valve may be rebuilt with the appropriate factory repair kit. 10. Slide new thrust washer over stem and insert assembly through ball cavity and fully up into stem hole recess. 3